Cogeneration plant utilizing paper residues in Çorlu, Turkey

EREN Holding and its affiliates operate in the energy, paper, packaging, retail, cement, textile, and tourism sectors. Modern Karton, a subsidiary of EREN Holding, is a major European paper manufacturer and the industry leader in Turkey. The company operates several paper machines at its production facilities in Çorlu, 90 km northwest of Istanbul. The facility produces 1.1 million tons per year of packaging papers and corrugated cardboard materials from waste paper. EREN Holding selected Outotec to design and build a new power plant on a turnkey basis. Completed in 2015, the plant uses by-products from the paper recycling process as fuel.

Summary

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Challenge

Thermal processing of solid fuel with a high degree of non-combustible debris

Strict emissions limits

Need for a strong financing partner

Solution

Turnkey power plant solution utilizing paper mill by-products

Thermal treatment of solid fuel in Outotec Fluidized Bed

Incinerator with open-nozzle grid

Production of electricity and/ or export steam dependent on demand

Benefits

Avoids landfill disposal costs for waste production

Saves natural gas for steam or power generation

Produces minimal environmental emissions

OUTOTEC SLUDGE AND WASTE INCINERATION PLANT PROCESS

Paper mill rejects and sludge are transported via trucks and conveyors to a bunker system. The fuels are fed by a crane into an intermediate dosing hopper, from where they are transported to a bubbling fluidized bed (FB) incinerator.

The refractory-lined incinerator, equipped with an air pre-heater and flue gas recycling, allows highly flexible operation in terms of the feed material.

Outotec’s open-nozzle grid configuration allows debris such as metals, glass, and stones to be removed during operation. The heat recovery boiler, which consists of an evaporator, super heater, and economizer, uses the hot flue gases from the FB incinerator to produce steam for the turbine. An external superheater increases the live steam temperature to achieve high turbine efficiency.

The flue gas enters the baghouse when leaving the economizer, and lime and activated carbon are added to clean the flue gas. The de-dusted flue gas then passes a condensate preheater and leaves the plant via a stack.

Project scope

Outotec’s turnkey solution encompassed everything from the plant equipment engineering through to delivery of the complete process, including startup and operator training.